Drywall patch kit systems

ABSTRACT

The drywall repair system comprises at least one drywall patch template. The drywall patch template comprises a square made of gypsum plaster as cut to a pre-determined repair-area-size, which is pressed between a first and a second paper boundary sheet layer. The first paper boundary sheet layer extends outwardly from the outer edge of the square made of gypsum plaster thereby creating a perimeter frame and comprises an area larger than the second paper boundary sheet layer which does not extend outwardly from the outer edge of the square made of gypsum plaster. The first paper boundary sheet layer, when the drywall patch template is installed, comprises tier which is located in front of the drywall wall and the square made of gypsum plaster is located within and adjacent the pre-cut hole in the drywall wall.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is related to and claims priority from prior provisional application Ser. No. 61/377,095, filed Aug. 26, 2010 which application is incorporated herein by reference.

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR 1.71(d).

BACKGROUND OF THE INVENTION

The following includes information that may be useful in understanding the present invention(s). It is not an admission that any of the information provided herein is prior art, or material, to the presently described or claimed inventions, or that any publication or document that is specifically or implicitly referenced is prior art.

1. FIELD OF THE INVENTION

The present invention relates generally to devices for repairing holes in walls and more specifically relates to a drywall patch kit for patching holes in drywalls.

2. DESCRIPTION OF THE RELATED ART

Drywall, also known as plasterboard or gypsum board, comprises a panel made of gypsum plaster pressed between two thick sheets of paper. It is used to make interior walls and ceilings. One of the positive aspects of drywall is that it is easy to install. An entire house can be dry-walled in one or two days by two experienced workers. Drywall is easy enough to use that it can be installed by many amateur home carpenters.

Unfortunately, drywall is relatively soft and can be easily damaged. The damage can either be minor, like nail pops, dings or hairline stress cracks, or it can be rather extensive. Stubborn wallpaper removal, water, or direct impact may cause significant drywall damage. Repairing drywall is not always easy, and it may be hard to estimate how much time and which materials will be required. Usually a drywall repair includes cutting out a square area with clean edges around the damaged portion, cutting out a patch piece, placing the patch piece into the wall via screwing and mudding, and finally sanding away excess mud, smoothing out the wall, and repainting the repaired area.

Unfortunately repairing drywall can require various tools and components and can be time consuming and relatively messy. Therefore a need exists for a reliable drywall patch kit for patching holes in drywalls. A further need exists for a drywall patch kit which facilitates a fast and easy drywall repair which saves time and money.

Various attempts have been made to solve the above-mentioned problems such as those found in U.S. Pat. Nos. 4,358,495, 4,620,407, and 5,960,603. This prior art is representative of devices for repairing holes in walls. None of the above inventions and patents, taken either singly or in combination, is seen to describe the invention as claimed.

Ideally, a drywall patch kit should be easy to use, save the user time, function reliably and be manufactured at a modest expense. Thus, a need exists for a reliable Drywall Patch Kit System to easily patch holes in drywalls and to avoid the above-mentioned problems.

BRIEF SUMMARY OF THE INVENTION

In view of the aforementioned disadvantages inherent in the known devices for repairing holes in walls art, the present invention provides a novel Drywall Patch Kit System. The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a reliable and easy to use drywall patch kit for patching holes in drywalls.

A drywall repair system is disclosed herein comprising at least one drywall patch template. The drywall patch template comprises a square made of gypsum plaster as cut to a pre-determined repair-area-size, which is pressed between a first paper boundary sheet layer and a second paper boundary sheet layer.

The square made of gypsum plaster comprises an outer edge defining the pre-determined repair-area-size and a thickness equal to or less than a drywall wall. The first paper boundary sheet layer extends outwardly from the outer edge of the square made of gypsum plaster thereby creating a perimeter frame, and comprises an area larger than the second paper boundary sheet layer. The second paper boundary sheet layer does not extend outwardly from the outer edge of the square made of gypsum plaster.

The first paper boundary sheet layer frames the square made of gypsum plaster such that the drywall patch template can be inserted into a pre-cut hole in a drywall wall to serve as a substantially-flush repair. The first paper boundary sheet layer, when the drywall patch template is installed, comprises tier which is located in front of the drywall wall as a substantially-flush repair and the square made of gypsum plaster is located within and adjacent the pre-cut hole in the drywall wall. The tier in combination with a drywall mud compound prevents the square made of gypsum plaster from falling in and behind the pre-cut hole in the drywall wall, thereby maintaining an adjacent relationship between the drywall patch template and the drywall wall for an extended duration.

A kit is also described herein including at least one utility knife; at least one putty knife; drywall mud compound; a set of drywall patch templates; and a set of user instructions comprising an instructional DVD.

A preferred method of use is further disclosed herein comprising the following steps: measuring and cutting a square hole in a damaged wall, wherein the damaged wall comprises drywall, thereby creating a pre-cut hole in the damaged wall; applying a drywall mud compound around the edges of the pre-cut hole; inserting a drywall patch template into the pre-cut hole with a first paper boundary sheet layer of the drywall patch template located in front of the damaged wall, and a square made of gypsum plaster as a backing to the first paper boundary sheet layer inside and adjacent to the damaged wall; applying a drywall mud compound to an outer surface of the first paper boundary sheet layer to affix the drywall patch template to the damaged wall to create a repair to the damaged wall; and sanding and finishing the drywall mud compound to provide a substantially flush finish to the repair to the damaged wall.

The present invention holds significant improvements and serves as a Drywall Patch Kit System. For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. The features of the invention which are believed to be novel are particularly pointed out and distinctly claimed in the concluding portion of the specification. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The figures which accompany the written portion of this specification illustrate embodiments and a method of use for the present invention, Drywall Patch Kit Systems, constructed and operative according to the teachings of the present invention.

FIG. 1 shows a perspective view illustrating a Drywall Patch Kit System according to an embodiment of the present invention.

FIG. 2 is a perspective view illustrating the Drywall Patch Kit System in an in-use condition according to an embodiment of the present invention of FIG. 1.

FIG. 3 is a perspective view illustrating the Drywall Patch Kit System in another in-use condition according to an embodiment of the present invention of FIG. 1.

FIG. 4 is a perspective view illustrating the Drywall Patch Kit System in yet another in-use condition according to an embodiment of the present invention of FIG. 1.

FIG. 5 is a flowchart illustrating a method of using the Drywall Patch Kit System according to an embodiment of the present invention of FIG. 1.

The various embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements.

DETAILED DESCRIPTION

As discussed above, embodiments of the present invention relate to devices for repairing holes in walls and more specifically relate to a drywall patch kit for patching holes in drywalls.

Referring to the drawings by numerals of reference there is shown in FIG. 1, a perspective view illustrating Drywall Patch Kit System 100 according to an embodiment of the present invention.

Drywall Patch Kit System 100 comprises at least one drywall patch template 120. Drywall patch template 120 comprises square made of gypsum plaster 130 as cut to pre-determined repair-area-size 140. Pre-determined repair-area-size 140 may preferably be of square shape and measure four inches by four inches, six inches by six inches, eight inches by eight inches, ten inches by ten inches, twelve inches by twelve inches, fourteen inches by fourteen inches, or sixteen inches by sixteen inches. However, square made of gypsum plaster 130 may alternatively comprise a rectangular shape. Further, square made of gypsum plaster 130 may alternatively be made of fiberglass or other suitable materials.

Square made of gypsum plaster 130 is pressed between first paper boundary sheet layer 150 and second paper boundary sheet layer 160. Square made of gypsum plaster 130 thereby comprises a small sheet of drywall which is typically made of gypsum plaster pressed between two thick sheets of paper. Square made of gypsum plaster 130 comprises outer edge 170 defining pre-determined repair-area-size 140. Drywall Patch Kit System 100 comprises a series of drywall patch templates 120 of various sizes so as to provide user 250 with a selection of patches to choose from. User 250 may measure the size of the hole or break in the wall and simply pick a matching drywall patch template 120. This may save user 250 time and effort, since user 250 doesn't have to manually cut out an appropriately sized patch.

First paper boundary sheet layer 150 extends outwardly from outer edge 170 of square made of gypsum plaster 130 thereby creating tier 210 and perimeter frame 180. Perimeter frame 180 preferably comprises a width of two inches. Second paper boundary sheet layer 160 does not extend outwardly from outer edge 170 of square made of gypsum plaster 130. An appropriately sized square may be cut from the wall so as to create pre-cut hole 190. First paper boundary sheet layer 150 frames square made of gypsum plaster 130 such that drywall patch template 120 can be inserted into pre-cut hole 190 in a drywall wall to serve as a substantially-flush repair.

Square made of gypsum plaster 130 preferably has a depth of at least ½ inch so that square made of gypsum plaster 130 approximately matches the thickness of drywall wall. However, square made of gypsum plaster 130 preferably comprises a thickness equal to or less than a drywall wall. Square made of gypsum plaster 130 may be inserted into pre-cut hole 190 so that perimeter frame 180 extents over the edges of pre-cut hole 190. Perimeter frame 180 thereby is located in front of the drywall wall as a substantially-flush repair and square made of gypsum plaster 130 is located within and adjacent pre-cut hole 190 in drywall wall.

Tier 210, in combination with drywall mud compound 220, which may be applied around the edges of pre-cut hole 190, on square made of gypsum plaster 130, and on perimeter frame 180, prevents square made of gypsum plaster 130 from falling in and behind pre-cut hole 190 into drywall wall, thereby maintaining an adjacent relationship between drywall patch template 120 and drywall wall for an extended duration.

Drywall Patch Kit System 100 may be sold as kit 400 comprising the following parts: at least one utility knife 230; at least one putty knife 240; at least one bucket of drywall mud compound 220; a set of several drywall patch templates 120; and a set of user instructions, wherein user instructions comprise an instructional DVD. Kit 400 therefore comprises all materials needed to repair a hole in a drywall. There is no need to purchase and carry separate items which may usually be necessary for this type of repair. User 250 is not obliged to investigate which materials are necessary for a drywall repair and may instead simply purchase drywall repair system 110. Kit 400 further comprises an instructional DVD which explains an effective way to do a drywall repair and thereby further eases the repair process.

Referring now to FIGS. 2 and 3, perspective views illustrating Drywall Patch Kit System 100 in an in-use condition 600 according to an embodiment of the present invention of FIG. 1.

An appropriately sized square may be cut around the hole in the drywall wall so as to create pre-cut hole 190. User 250 then picks the appropriate pre-sized drywall patch template 120 comprising square made of gypsum plaster 130 and first paper boundary sheet layer 150. First paper boundary sheet layer 150 extends outwardly from outer edge 170 of square made of gypsum plaster 130 thereby creating tier 210 and perimeter frame 180. A coat of drywall mud compound 220 may be applied around the edges of pre-cut hole 190. After that, square made of gypsum plaster 130 may be inserted into pre-cut hole so that perimeter frame 180 extents over the edges of pre-cut hole 190 and thereby prevents square made of gypsum plaster 130 from falling in and behind pre-cut hole 190 in drywall wall. Perimeter frame 180 thereby is located in front of the drywall wall to facilitate a substantially-flush repair and square made of gypsum plaster 130 is located within and adjacent pre-cut hole 190 in drywall wall.

Referring now to FIG. 4, a perspective view illustrating Drywall Patch Kit System 100 in an in-use condition 600 according to an embodiment of the present invention of FIG. 1.

Kit 400 comprises all materials needed to repair a hole in a drywall, such as putty knife 240, bucket of drywall mud compound 220, and several drywall patch templates 120. After the right sized drywall patch template 120 has been inserted into pre-cut hole 190 so that perimeter frame 180 extends over and beyond the edges of pre-cut hole 190, perimeter frame 180 is now located in front of the drywall wall as a substantially-flush repair, and user may now add a coat of drywall mud compound 220 over drywall patch template 120 and drywall wall. After allowing drywall mud compound 220 to dry, user 250 may sand away excess mud and smooth out the drywall wall.

Drywall Patch Kit System 100 may be manufactured and provided for sale in a wide variety of sizes and shapes for a wide assortment of applications. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other kit contents or arrangements such as, for example, including more or less components, customized parts, different color combinations, parts may be sold separately, etc., may be sufficient.

Referring now to FIG. 5, a flowchart 500 illustrating a method 550 of using Drywall Patch Kit System 100 according to an embodiment of the present invention of FIG. 1.

In accordance with the embodiments of the present invention a preferred method of use 550 is disclosed herein comprising: step one 501 measuring and cutting a square hole in a damaged wall, wherein the damaged wall comprises drywall, thereby creating pre-cut hole 190 in the damaged wall; step two 502 applying a drywall mud compound around the edges of pre-cut hole 190; step three 503 inserting drywall patch template 120 into pre-cut hole 190 with first paper boundary sheet layer 150 of drywall patch template 120 located in front of the damaged wall, and square made of gypsum plaster 130 as a backing to first paper boundary sheet layer 150 inside and adjacent to the damaged wall; step four 504 applying drywall mud compound 220 to outer surface 200 of first paper boundary sheet layer 150 to affix drywall patch template 120 to the damaged wall to create a repair to the damaged wall; and step five 505 sanding and finishing drywall mud compound 220 to provide a substantially flush finish to the repair to the damaged wall.

It should be noted that the steps described in the method of use can be carried out in many different orders according to user preference. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods of use arrangements such as, for example, different orders within above-mentioned list, elimination or addition of certain steps, including or excluding certain maintenance steps, etc., may be sufficient.

The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. 

What is claimed is new and desired to be protected by Letters Patent is set forth in the appended claims:
 1. A drywall repair system comprising: at least one drywall patch template; wherein said drywall patch template comprises a square made of gypsum plaster as cut to a pre-determined repair-area-size, said square made of gypsum plaster pressed between at least a first paper boundary sheet layer and at least a second paper boundary sheet layer; wherein said square made of gypsum plaster comprises an outer edge defining said pre-determined repair-area-size; wherein said first paper boundary sheet layer extends outwardly from said outer edge of said square made of gypsum plaster thereby creating a perimeter frame; wherein said second paper boundary sheet layer does not extend outwardly from said outer edge of said square made of gypsum plaster; and wherein said first paper boundary sheet layer frames said square made of gypsum plaster such that said drywall patch template can be inserted into a pre-cut hole in a drywall wall to serve as a substantially-flush repair.
 2. The drywall repair system of claim 1 wherein said square comprises fiberglass.
 3. The drywall repair system of claim 1 wherein said square made of gypsum plaster comprises said repair-area-size, wherein said repair-area-size is about four inches by about four inches.
 4. The drywall repair system of claim 1 wherein said square made of gypsum plaster comprises said repair-area-size, wherein said repair-area-size is about six inches by about six inches.
 5. The drywall repair system of claim 1 wherein said square made of gypsum plaster comprises said repair-area-size, wherein said repair-area-size is about eight inches by about eight inches.
 6. The drywall repair system of claim 1 wherein said square made of gypsum plaster comprises said repair-area-size, wherein said repair-area-size is about ten inches by about ten inches.
 7. The drywall repair system of claim 1 wherein said square made of gypsum plaster comprises said repair-area-size, wherein said repair-area-size is about twelve inches by about twelve inches.
 8. The drywall repair system of claim 1 wherein said square made of gypsum plaster comprises said repair-area-size, wherein said repair-area-size is about fourteen inches by about fourteen inches.
 9. The drywall repair system of claim 1 wherein said square made of gypsum plaster comprises said repair-area-size, wherein said repair-area-size is about sixteen inches by about sixteen inches.
 10. The drywall repair system of claim 1 wherein said drywall patch template comprising said square made of gypsum plaster comprises a rectangular cross-section wherein a first and a second side are equal in length, and a third and a fourth side are equal in length, wherein said first and said second side are parallel to each other and said third and said fourth side are parallel to each other and wherein said first and said second side comprise a different length than said third and said fourth side.
 11. The drywall repair system of claim 1 wherein said first paper boundary sheet layer comprises an area larger than said second paper boundary sheet layer.
 12. The drywall repair system of claim 11 wherein said first paper boundary sheet layer, when said drywall patch template is installed, comprises an outer surface.
 13. The drywall repair system of claim 12 wherein said first paper boundary sheet layer, when said drywall patch template is installed, comprises tier.
 14. The drywall repair system of claim 13 wherein said tier comprises said perimeter frame.
 15. The drywall repair system of claim 14 wherein said tier is located in front of said drywall wall as a substantially-flush repair and said square made of gypsum plaster is located within and adjacent said pre-cut hole in said drywall wall.
 16. The drywall repair system of claim 14 wherein said tier in combination with a drywall mud compound prevents said square made of gypsum plaster from falling in and behind said pre-cut hole in said drywall wall, thereby maintaining an adjacent relationship between said drywall patch template and said drywall wall for an extended duration.
 17. The drywall repair system of claim 1 wherein said second paper boundary sheet layer, when said drywall patch template is installed, comprises an inner surface and wherein said square made of gypsum plaster comprises a thickness equal to or less than said drywall wall.
 18. A drywall repair system comprising: at least one drywall patch template; wherein said drywall patch template comprises a square made of gypsum plaster as cut to a pre-determined repair-area-size, said square made of gypsum plaster pressed between at least a first paper boundary sheet layer and at least a second paper boundary sheet layer; wherein said square made of gypsum plaster comprises an outer edge defining said pre-determined repair-area-size and a thickness equal to or less than a drywall wall; wherein said first paper boundary sheet layer extends outwardly from said outer edge of said square made of gypsum plaster thereby creating a perimeter frame and said first paper boundary sheet layer comprises an area larger than said second paper boundary sheet layer; wherein said second paper boundary sheet layer does not extend outwardly from said outer edge of said square made of gypsum plaster; wherein said first paper boundary sheet layer frames said square made of gypsum plaster such that said drywall patch template can be inserted into a pre-cut hole in a drywall wall to serve as a substantially-flush repair; and wherein said first paper boundary sheet layer, when said drywall patch template is installed, comprises tier which is located in front of said drywall wall as a substantially-flush repair and said square made of gypsum plaster is located within and adjacent said pre-cut hole in said drywall wall and said tier in combination with a drywall mud compound prevents said square made of gypsum plaster from falling in and behind said pre-cut hole in said drywall wall, thereby maintaining an adjacent relationship between said drywall patch template and said drywall wall for an extended duration.
 19. The drywall repair system of claim 18 further comprising a kit, wherein said kit includes: a utility knife; a putty knife; said drywall mud compound; a set of said drywall patch templates; and a set of user instructions, wherein said user instructions comprise an instructional DVD.
 20. A method for using a drywall repair system comprising the steps of: measuring and cutting a square hole in a damaged wall, wherein said damaged wall comprises drywall, thereby creating a pre-cut hole in said damaged wall; applying a drywall mud compound around the edges of said pre-cut hole; inserting a drywall patch template into said pre-cut hole with a first paper boundary sheet layer of said drywall patch template located in front of said damaged wall, and a square made of gypsum plaster as a backing to said first paper boundary sheet layer inside and adjacent to said damaged wall; applying a drywall mud compound to an outer surface of said first paper boundary sheet layer to affix said drywall patch template to said damaged wall to create a repair to said damaged wall; and sanding and finishing said drywall mud compound to provide a substantially flush finish to said repair to said damaged wall. 